Sapcer pin arrangement for helical gear differential

ABSTRACT

An axle assembly that includes a differential case which is rotatable about an axis, a pair of side gears that are disposed within the differential case, a spacer ring and a cross pin. The spacer ring is disposed between the side gears. The cross pin is fixed to one of the differential case and the spacer ring and extends through the spacer ring. The aperture in the spacer that receives the cross pin may be larger than the cross pin so that the spacer ring can control end play of the side gears independently of the cross pin.

CROSS-REFERENCE TO RELATED APPLICATIONS

This is a continuation-in-part of U.S. patent application Ser. No.11/584,389 filed Oct. 20, 2006, which is a continuation of U.S. patentapplication Ser. No. 11/343,855 filed Jan. 31, 2006, now U.S. Pat. No.7,147,585 which is a continuation of U.S. patent application Ser. No.10/794,780 filed Mar. 5, 2004, now U.S. Pat. No. 7,022,041. Thedisclosures of the above applications are incorporated herein byreference.

FIELD OF THE DISCLOSURE

The present disclosure relates to differentials for use in automotivedrivelines and, more particularly, to a spacer pin assembly for use inC-clip parallel-axis helical differentials which functions to provideindependent control of side gear endplay and axleshaft endplay.

BACKGROUND OF THE DISCLOSURE

Differentials of the type used in automotive drivelines generallyinclude a planetary gearset supported within a differential case tofacilitate relative rotation (i.e., speed differentiation) between apair of output shafts. In some differential, the planetary gearsetincludes helical side gears fixed to the ends of the output shafts andwhich are meshed with paired sets of helical pinion gears. This type ofdifferential is known as a parallel-axis helical differential. Inresponse to input torque applied to the differential case, the torquetransmitted through meshed engagement of the side gears and pinion gearsgenerates thrust forces. To accommodate these and other operatingforces, the wall surface of the gear pockets and other thrust surfacesof the differential case must provide adequate support.

In some differentials, it is necessary to install C-shaped retainers, orC-clips, for restraining and positioning the output shafts in thedifferential. To install the C-clips, it is necessary to gain access tothe interior cavity of the differential case through an access window.In general, it is desirable to allow the side gear thrust load to bedistributed evenly around the periphery of the differential. One way toachieve such even load distribution is to position the pinion pairsevenly around the periphery of the differential case. However, becausethe access window is provided in the differential case, there tends tobe incompatibility issues with placement of the pinion pairs.

SUMMARY OF THE DISCLOSURE

In one form, the present invention provides an axle assembly for avehicle that includes a pair of axleshafts and a differential assemblyhaving differential case, a pair of side gears, and a spacer pinassembly. The differential case is rotatable about an axis and includesa first pin aperture. The side gears are rotatably disposed within thedifferential case. Each axleshaft is coupled for rotation with one ofthe side gears. The spacer pin assembly includes a spacer that isdisposed between the side gears and which has a second pin aperture. Across pin is received in the first and second pin apertures such thatreceipt of the cross pin in the first pin aperture fixedly but removablycouples the cross pin to the differential case. The size of the secondpin aperture formed in the spacer is greater than a corresponding sizeof the cross pin such that the spacer is axially moveable along therotational axis of the differential case relative to the cross pin. Assuch, the cross pin functions to limit lateral movement of theaxleshafts in a direction toward one another while the spacer functionsto limit movement of the side gears toward one another independently ofthe cross pin.

In another form, the present invention provides a method that includes:providing a differential case having a rotational axis; installing apair of side gears within the differential case; installing a pair ofaxleshafts within the differential case such that each axleshaft iscoupled for rotation with one of the side gears; locating a spacerbetween the side gears; fixedly coupling a cross pin to the differentialcase such that the cross pin is inserted through a pin aperture in thespacer; and moving the side gears and the spacer in a first directionalong the rotational axis without moving the cross pin.

In yet another form, the present invention provides an axle assembly fora vehicle that includes a pair of axleshafts and a differential assemblyhaving a differential case, a pair of side gears, and a spacer pinassembly. The differential case is rotatable about an axis and includesa first pin aperture. The side gears are rotatably disposed within thedifferential case. Each axleshaft is coupled for rotation with one ofthe side gears. The spacer pin assembly includes a spacer that isdisposed between the side gears and includes a second pin aperture. Across pin is received in the first and second pin apertures. Receipt ofthe cross pin in the first pin aperture fixedly but removably couplesthe cross pin to the differential case. The size of the second pinaperture is greater than a corresponding size of the cross pin such thata void space is disposed between the spacer and the cross pin regardlessof the axial position of the side gears along the rotational axis.

In accordance with yet another form, the present invention provides anaxle assembly for a vehicle that includes a pair of axleshafts and adifferential assembly having a differential case, a pair of side gears,and a spacer pin assembly. The differential case is rotatable about anaxis and includes a case pin aperture. The side gears are rotatablydisposed within the differential case. Each axleshaft is coupled forrotation with one of the side gears. The spacer pin assembly includes aspacer ring that is disposed between the side gears and includes firstand second spacer pin apertures. A cross pin is inserted into thedifferential case through the case pin aperture and is retained withinthe first and second spacer pin apertures in the spacer ring.Thereafter, the cross pin is secured to the differential case forremoveably coupling the spacer pin assembly to the differential case.

In accordance with another embodiment of the present invention, thedifferential assembly includes a pair of side gears rotatably disposedin the differential case and a spacer pin assembly disposed between theside gears. The spacer pin assembly includes a spacer ring non-rotatablyretained within the differential case and a cross pin having itsopposite ends retained in apertures formed in the spacer ring. The crosspin is removeably secured to the spacer ring.

Further areas of applicability of the present disclosure will becomeapparent from the detailed description provided hereinafter. It shouldbe understood that the detailed description and specific examples, whileindicating the preferred embodiment of the disclosure, are intended forpurposes of illustration only and are not intended to limit the scope ofthe disclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

The present disclosure will become more fully understood from thedetailed description and the accompanying drawings, wherein:

FIG. 1 is a schematic view of an exemplary motor vehicle into which adifferential assembly constructed in accordance with the teachings ofthe present disclosure is incorporated;

FIG. 2 a is a perspective view of the differential assembly of FIG. 1;

FIG. 2 b is a perspective view of the differential case associated withthe differential assembly of FIG. 2 a;

FIG. 3 is an exploded view of the differential assembly shown in FIG. 2a;

FIG. 4 is a sectional view of the differential assembly taken along line4-4 of FIG. 2 a;

FIG. 5 is a sectional view of the differential assembly taken along line5-5 of FIG. 4;

FIG. 6 is a perspective view of the differential assembly of FIG. 1illustrating the cross pin of the spacer pin assembly in an explodedcondition;

FIG. 7 is a perspective view of the differential assembly of FIG. 1illustrating the cross pin of the spacer pin assembly engaged with thecylindrical boss of the differential case;

FIG. 8 is a perspective view of the differential assembly of FIG. 2 aillustrating the cross pin of the spacer pin assembly in an installedcondition;

FIG. 9 is an exploded view of a differential assembly equipped with aspacer pin assembly constructed according to an alternative embodiment;

FIG. 10 is an exploded view of a differential assembly equipped with aspacer pin assembly constructed according to another alternativeembodiment;

FIG. 11 is an exploded view of the differential assembly equipped with aspacer pin assembly constructed according to yet another alternativeembodiment; and

FIGS. 12 and 13 illustrate alternative versions of a spacer pin assemblyadapted for use in the differential assembly pursuant to the presentinvention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The following description of the preferred embodiments is merelyexemplary in nature and is in no way intended to limit the disclosure,its application, or uses. The differential assembly according to thepresent teachings may be utilized with a wide variety of applicationsand is not intended to be specifically limited to the particularapplication recited herein.

With initial reference to FIG. 1, a drivetrain 10 for an exemplary motorvehicle is shown to include an engine 12, a transmission 14 having anoutput shaft 16, and a propeller shaft 18 connecting output shaft 16 toa pinion shaft 20 of a rear axle assembly 22. Rear axle assembly 22includes an axle housing 24, a differential assembly 26 rotatablysupported in axle housing 24, and a pair of axleshaft assemblies 28 and30, respectively, interconnected to left and right rear wheels 32 and34, respectively. Pinion shaft 20 has a pinion gear 36 fixed theretowhich drives a ring gear 38 that is fixed to a differential case 40 ofdifferential assembly 26. Differential case 40 is rotatably supported inaxle housing 24. A gearset 42 supported within differential case 40transfers rotary power from case 40 to a pair of output shafts 44 and 45associated with axleshaft assemblies 28 and 30, respectively, andfacilitates relative rotation (i.e., differentiation) therebetween.While differential assembly 26 is shown in a rear-wheel driveapplication, the present invention is contemplated for use indifferential assemblies installed in transaxles for use in front-wheeldrive vehicles, and/or in transfer cases for use in four-wheel drivevehicles.

Turning now to FIGS. 2 a through 5, differential assembly 26 will bedescribed in further detail. Differential assembly 26 is a parallel-axishelical-gear type differential and includes differential case 40 whichdefines an internal chamber 48. Differential case 40 includes a maindrum or body 46 and an end cap 50, each of which having respectivemating radial flanges 52 and 54, respectively. Radial flanges 52 and 54are secured together by a plurality of bolts (not shown) extendingthrough aligned mounting bores 58. As is known, a ring or bevel gear,such as ring gear 38, can be fixed to radial flange 52 on differentialcase 40 to transfer rotary power (i.e., drive torque) thereto.Differential case 40 defines a pair of axially aligned openings 60 a and60 b in communication with internal chamber 48. Axially aligned openings60 a and 60 b are adapted to receive and rotatably support end segmentsof output shafts 44 and 45 which are coupled to or integrally formedwith axleshafts 28 and 30.

With specific reference to FIGS. 3 and 4, differential assembly 26includes gearset 42 for transferring drive torque from differential case40 to output shafts 44 and 45 in a manner that facilitates speeddifferential therebetween. Gearset 42 may be a helical-type and isdisposed within internal chamber 48. Gearset 42 includes a pair of sidegears 68 a and 68 b. Side gears 68 a and 68 b have internal splines 70 aand 70 b adapted to mesh with external splines, not specifically shown,on the corresponding end segments of output shafts 44 and 45. Inaddition, side gears 68 a and 68 b include axial hubs 78 a and 78 b,respectively, which are retained in corresponding annular sockets formedin main body 46 and end cap 50 of differential case 40. Side gears 68 aand 68 b also are formed to define annular chambers 82 a and 82 b. Aswill be described in greater detail below, a spacer 86 of a spacer pinassembly is located between side gears 68 a and 68 b for limiting theamount of axial endplay of side gears 68 a and 68 b within differentialcase 40. The spacer pin assembly further includes a cross pin 90 whichextends through a clearance aperture 92 in U-shaped spacer 86 andfunctions to control endplay of axleshafts 44 and 45.

C-shaped retainers, commonly referred to as C-clips 94, are retained inannular chambers 82 a and 82 b and retention grooves formed in the endsegments of axleshafts 44 and 45 for preventing axleshafts 44 and 45from becoming unintentionally disengaged with side gears 68 a and 68 b.As such, C-clips 94 function to releaseably couple axleshafts 44 and 45to differential assembly 26. Side gears 68 a and 68 b may be bounded attheir outer ends by washers 96.

Gearset 42 is shown to also include four sets of helical pinion pairs,100 a and 100 b, 102 a and 102 b, 104 a and 104 b, and 106 a and 106 b,respectively (FIG. 3). For clarity, pinion pairs 100 a and 100 b, 102 aand 102 b, 104 a and 104 b and 106 a and 106 b are hereinafter referredto as a first, second, third and fourth pairs of pinion gears 100, 102,104 and 106, respectively. Brake shoes 100 a′ through 106 b′ cooperatewith respective pinion gears 100 through 106.

In FIGS. 2 b and 3, the four sets of helical pinion pairs 100 through106 are shown to be rotatably supported in complementary sets ofcylindrical pinion bores 110 a and 110 b, 112 a and 112 b, 114 a and 114b, and 116 a and 116 b. Pinion pairs 100 through 106 are also rotatablysupported on arcuate scalloped segments 86′ of spacer 86 which, in turn,function to inhibit rotation of spacer 86 relative to differential case40. The complementary sets of pinion bores 110 a and 110 b, 112 a and112 b, 114 a and 114 b, and 116 a and 116 b are hereinafter referred toas a first, second, third and fourth pair of pinion bores 110, 112, 114,and 116, respectively. Pinion bores 110 through 116 are formed in raisedhub segments 120 of main body 46. Pinion bores 110 through 116 arearranged in paired sets such that they communicate with each other andwith internal chamber 48. In addition, pinion bores 110 through 116 arealigned substantially parallel to the rotational axis A of axleshafts 44and 45. A window opening 124 is formed through differential case 40between the first and fourth pairs of pinion gears 100 and 106.

With reference now primarily to FIG. 5, a preferred spatial relationshipfor the four sets of pinion pairs will be described. The four sets ofpinion bores 110 through 116, and as a result, the four pinion pairs 100through 106 (FIG. 3), are radially spaced evenly around differentialcase 40 opposite window opening 124. More specifically, first pair ofpinion bores 110 is offset a radial distance α1 from second pair ofpinion bores 112. Second pair of pinion bores 112 is offset a radialdistance α2 from third pair of pinion bores 114. Finally, third pair ofpinion bores 114 is offset a radial distance α3 from fourth pair ofpinion bores 116. As illustrated, the respective “α” distances are takenfrom the centerline of respective first bores 110 a through 110 d. Theradial offsets between pinion bores 110 and 112, 112 and 114, and 114and 116 may be approximately equivalent (e.g., α1=α2=α3). In the exampleprovided, α1, α2 and α3 are approximately 75 degrees.

With specific reference now to FIGS. 2 b, 4 and 6, the configuration ofwindow opening 124 and its cooperation with cross pin 90 will bedescribed. Window opening 124 includes an access passage 126 surroundedby a cylindrical boss 128 that is formed on an outer surface 130 ofdifferential case 40. Cylindrical boss 128 defines a counterbore 132having an inner radial engaging surface 136. Cylindrical boss 128includes a pair of aligned mounting bores 140 formed on raised flanges142 for receiving a fastener 146 (FIG. 8) therethrough. A ledge portion150 extends at least partially about window opening 124 inwardly ofcylindrical boss 128 on differential case 40.

Cross pin 90 generally includes a proximal head portion 154, anintermediate shank portion 158 and a distal end portion 162. Headportion 154 defines a body that extends generally transverse tolongitudinal axis of cross pin 90. Head portion 154 includes athroughbore 164 for receiving fastener 146. Head portion 154 may includearcuate ends 168 that may be slidably disposed against inner radialengaging surface 136 of counterbore 132 during assembly. A bottomsurface 170 of head portion 154 locates against ledge 150. Distal endportion 162 of cross pin 90 locates in a bore 172 formed in differentialcase 40.

Cross pin 90 may be unitarily formed or may comprise two or morecomponents. In the example provided, cross pin 90 is a two-pieceassembly comprising proximal head portion 154, which may be pressed ontoa discrete shank that defines both intermediate shank portion 158 anddistal end portion 162. It is appreciated that while distal end portion162 of cross pin 90 is shown stepped down from intermediate shankportion 158, cross pin 90 may comprise a uniform outer diameter. Forexample, an alternate pinion gear arrangement may be employed with adifferential assembly providing enough space to accommodate a cross pindefining a consistent outer diameter.

With reference to FIGS. 4 and 7, assembly of cross pin 90 intodifferential case 40 will now be described in greater detail. OnceC-clips 94 are installed with spacer 86 located between side gears 66 aand 66 b, spacer aperture 92 is aligned opposite window opening 124 ondifferential case 40. Distal end 162 and intermediate portion 158 ofcross pin 90 are inserted through window opening 124 and spacer aperture92. Distal end 162 of cross pin 90 is located in bore 172 indifferential case 40 opposite window opening 124. Bore 172 andcounterbore 132 function to pilot cross pin 90 during installation.Proximal head portion 154 may be inserted in an orientationsubstantially transverse to the axis A of differential case 40. In thisway, head portion 154 of cross pin 90 will not interfere with theadjacent ring gear 38 (FIG. 1) during installation.

As distal end 162 of cross pin 90 locates into bore 172, bottom surface170 of head portion 154 engages ledge 150 between counterbore 132 andwindow opening 124. Similarly, arcuate ends 168 of proximal head 154engage inner radial engaging surface 136 of counterbore 132. Proximalhead portion 154 may then be rotated from the position shown in FIG. 7into a substantially parallel orientation with the axis A ofdifferential 26 as illustrated in FIG. 8 until throughbore 164 alignswith mounting bores 140 in raised flanges 142 on cylindrical boss 128.During rotation of proximal head portion 154, inner radial engagingsurface 136 pilots arcuate ends 168 of proximal head portion 154.Concurrently, ledge 150 maintains cross pin 90 at proper depth andassures that throughbore 164 will be properly aligned with mountingbores 140 of raised flanges 142 on cylindrical boss 128.

Once throughbore 164 and mounting bores 140 are aligned to one another,fastener 146 is inserted and secured. With cross pin 90 thus installed,relative movement between cross pin 90 and differential case 40 isessentially inhibited. As a result, the endplay of the end segment ofaxleshafts 44 and 45 may be controlled within desirable tolerances as afunction of the diameter of intermediate portion 158 of cross pin 90.Spacer 86, shown to have a U-shaped configuration, is disposed betweenside gears 68 a and 68 b and controls axial endplay of side gears 68 aand 68 b to keep differential assembly 26 from binding. Cross pin 90does not engage spacer 86 in an assembled condition. Specifically, bore92 in spacer 86 defines a greater diameter than the diameter of crosspin 90. In this way, two distinct components are used to control theside gear endplay (namely, spacer 86), and the axleshaft endplay(namely, cross pin 90). Such an arrangement allows for a desired amountof side gear endplay without affecting the axleshaft endplay.

The mass of differential assembly 26 may be distributed to providerotational balance. Specifically, the mass of cylindrical boss 128 andcross pin head 154 cooperate with the mass of differential case 40around pinion bores 110 through 116 and mass of the pinion gears 100through 106 to provide a rotationally balanced differential assembly 26.Stated another way, the mass of the several components of differentialassembly 26 is distributed about the rotational axis A so as to minimizeor eliminate imbalance when the differential assembly 26 is rotatedabout the rotational axis A. It is appreciated that a counterweight mayadditionally, or alternatively be incorporated onto differential case 40or end cap 50 of the differential assembly 26.

The fastener 146 may be configured the same as an open differential suchthat the same axle assembly lines may be ran with both opendifferentials and helical gear differentials without changing tooling ortorque wrench settings.

Turning now to FIG. 9, a differential assembly 226 according to analternative embodiment is shown. Differential assembly 226 incorporatesmany components similar to differential assembly 26, with suchcomponents identified with a 200 prefix. Differential assembly 226includes a cross pin 290 having an intermediate shank portion 258 and adistal end portion 262. Distal end portion 262 of cross pin 290 isadapted to pass through aperture 92 in spacer 86 for retention in bore172 in differential case 240. Cross pin 290 may be adapted to beretained in differential case 240 by a retaining disk 234. Specifically,the proximal end of cross pin 290 is adapted to seat into a counterbore238 formed on an inboard surface of retaining disk 234. A retaining ring244 is adapted to seat into a radial lip or groove 248 arranged incounterbore 232 to removeably secure cross pin 290 and disk 234 todifferential case 290.

With reference now to FIG. 10, a differential assembly 326 according toanother alternative embodiment is shown. Differential assembly 326 alsoincorporates similar components to differential assembly 26, with suchcomponents identified with a 300 prefix. Differential assembly 326includes a cross pin 390 having an intermediate shank portion 358 and adistal end portion 362. Cross pin 390 is adapted to be retained indifferential case 340 by a L-plate 334 and a fastener 341. Specifically,a proximal end of cross pin 390 is adapted to pass through an opening338 formed in L-plate 334. In this way, L-plate 334 cooperates withcross pin 390 to maintain cross pin 390 in a substantially perpendicularorientation with axis A. Fastener 341 may be adapted to be securedthrough bores 348 incorporated in flange portions 332 and a passage 335formed in L-plate 334. As a result, in an installed position, fastener341 bounds the proximal end of cross pin 390 and maintains cross pin 390in an installed position.

With reference now to FIG. 11, a differential assembly 426 according toyet another alternative embodiment is shown. Differential assembly 426also incorporates many components that one similar to differentialassembly 26, with such components identified with a 400 prefix.Differential assembly 426 includes a cross pin 490 having anintermediate shank portion 458 and a distal end portion 462. Distal endportion 462 of cross pin 490 is adapted to pass through aperture 92 inspacer 86 for retention in bore 172 formed in differential case 440.Cross pin 490 is removeably retained in differential casing 440 by afastener 441. Specifically, fastener 441 is adapted to be securedthrough passages 448 incorporated in flange portions 432 and a bore 435formed in cross pin 490.

A pair of access passages 426 are incorporated in differential casing440 and define an access for installing C-clips 92 (FIG. 3). A spacer486 according to additional features includes a passage 492 foraccepting cross pin 490 therethrough in an assembled position. Spacer486 is adapted to be installed into differential casing 440 axiallybetween side gears as described herein. Spacer 486 includes U-shapedchannels 494 that are alignable with passages 492 to accept C-clips 92therein.

Each of the spacer pin assemblies discussed above functions to transferside gear thrust loads through the spacer instead of through the crosspin so as to avoid excessive loading on the C-clip retainers. However,care must be taken to ensure that the side gear thrust loads are notabsorbed by the C-clips. Thus, it is preferable that the side gearsengage the spacer before the ends of the axleshafts contact the crosspin. In terms of tolerance stack-ups, it is beneficial to have the sidegear spacer function and axleshaft spacer function integrated into acommon component or simplified assembly. Accordingly, FIGS. 12 and 13illustrate alternative space pin assemblies that are applicable for usein differential assembly 26 (FIGS. 2 through 8), differential assembly226 (FIG. 9), differential assembly 326 (FIG. 10) and differentialassembly 426 (FIG. 11). However, for purposes of clarity, thesealternative spacer pin assemblies will be described in combination withdifferential assembly 26.

Referring initially to FIG. 12, a spacer pin assembly 500 is shown toinclude a spacer ring 502 and a cross pin 504. Spacer ring 502 isadapted to be installed within internal chamber 48 of any of theabove-referenced differential assemblies between side gears 68 a and 68b. Spacer ring 502 includes a first end face surface 506 adapted to bealigned in proximity to an inner face surface of side gear 68 a and asecond end face surface 508 adapted to be aligned in proximity to aninner face surface of side gear 68 b. Spacer ring 502 further includes acircular outer surface defining four arcuate sections 510 a through 510d which are delimited by scalloped sections 512 a through 512 d whichalign with the paired sets of pinion bores 110 through 116 to inhibitrotation of spacer ring 502 within body 46 of differential case 40. Apair of polar apertures 514 and 516 are formed to extend through arcuatesections 510 a and 510 c, respectively, and are sized to receive crosspin 504 therein upon assembly of spacer assembly 500. In particular,spacer ring 502 is adapted for installation within chamber 48 ofdifferential case 40 such that arcuate section 510 a is aligned withwindow opening 124. As seen, end face surfaces 506 and 508 of spacerring 502 are laterally recessed adjacent to arcuate section 510 a todefine a pair of U-shaped channels 518 and 520 which are sized to permitinstallation of C-clips 94 through window 124.

Cross pin 504 is a cylindrical component having a mounting bore 520 thatis adapted to receive a fastener for removeably securing cross pin 504to differential case 40. Upon assembly, spacer ring 502 is disposed withchamber 48 of differential case 40 such that cross pin 504 is installedthrough access window 124 in differential case 40 and passes throughpolar apertures 514 and 516 in spacer ring 502. A first end 522 of crosspin 504 is located in bore 172 of differential case 40 while itsopposite end 524 extends into window 124.

Thereafter, mounting bore 520 is aligned with mounting bores in thedifferential case. Assuming spacer pin assembly 500 is used withdifferential assembly 26, mounting bore 520 in cross pin 504 is alignedwith bores 140 in flanges 142 on boss 128 of differential case 40 andfastener 146 is thereafter installed into the aligned bores. However,since cross pin 504 does not include a head portion similar to thatassociated with cross pin 90 of FIGS. 2 through 8, it is contemplatedthat window opening 124 could be of reduced size or simply replaced witha window configuration similar to the window shown in FIG. 11 fordifferential assembly 426. Furthermore, it is contemplated that athreaded fastener 146, 341 or 441 could be replaced with a press-fitroll-pin for removeably securing cross pin 504 to case 40. Finally, itis again reiterated that the retaining disk type cross pin retentionsystem used in association with differential assembly 226 of FIG. 9, theL-plate cross pin retention system used in association with differentialassembly 326 of FIG. 10, and the guided retention system associated withdifferential assembly 426 of FIG. 11 can be used with spacer pinassembly 500. In each case, the width of spacer ring 502 is selected toensure side gear engagement prior to axleshaft contact with cross pin504.

As a substitute for spacer pin assembly 500 shown in FIG. 12, analternative arrangement is shown in FIG. 13 and identified by referencenumber 500′. Spacer pin assembly 500′ is generally similar to spacer pinassembly 500 except that cross pin 504′ is shorter in length such thatits mounting bore 520 is now alignable with a pair of mounting holes 530formed through arcuate section 510 a′ of spacer ring 502′. As such,cross pin 504′ is removeably secured to spacer ring 502′ via insertionof a removeable fastener, such as a lock pin, into aligned bore 520′ andholes 530. With such an arrangement, the size and function of window 124in differential case 40 can be revised to accommodate installation andremoval of C-clips 94.

While the disclosure has been described in the specification andillustrated in the drawings with reference to various embodiments, itwill be understood by those skilled in the art that various changes maybe made and equivalents may be substituted for elements thereof withoutdeparting from the scope of the disclosure as defined in the claims.Furthermore, the mixing and matching of features, elements and/orfunctions between various embodiments is expressly contemplated hereinso that one of ordinary skill in the art would appreciate from thisdisclosure that features, elements and/or functions of one embodimentmay be incorporated into another embodiment as appropriate, unlessdescribed otherwise, above. Moreover, many modifications may be made toadapt a particular situation or material to the teachings of thedisclosure without departing from the essential scope thereof.Therefore, it is intended that the disclosure not be limited to theparticular embodiment illustrated by the drawings and described in thespecification as the best mode presently contemplated for carrying outthis disclosure, but that the disclosure will include any embodimentsfalling within the foregoing description and the appended claims.

1. A differential assembly, comprising: a case having first and secondcase apertures communicating with an internal chamber; a pair of outputshafts having end segments disposed within said chamber; a gearsetdisposed in said chamber for transmitting drive power from said case tosaid output shafts while permitting speed differentiation therebetweenand including a pair of laterally-spaced side gears coupled to said endsegments of said output shafts; and a spacer pin assembly having aspacer ring, a cross pin and a fastener, said spacer ring is disposed insaid chamber between said side gears and has first and second spacerapertures alignable with said first and second case apertures, saidcross pin is disposed within said aligned first and second caseapertures and said first and second spacer apertures, and wherein saidfastener secures said cross pin to said case.
 2. The differentialassembly of claim 1 wherein said first case aperture in said casedefines a window opening that is sized to permit insertion of C-clipretainers into said internal chamber for securing said output shafts tosaid side gears.
 3. The differential assembly of claim 2 wherein saidspacer ring includes channels adapted to surround said C-clips.
 4. Thedifferential assembly of claim 1 wherein said case defines elongatedbores, and wherein said gearset further includes pinion gears eachmeshed with at least one of said side gears which are rotatablysupported in said bores so as to generally surround said spacer ring. 5.The differential assembly of claim 4 wherein said spacer ring hasscalloped outer surface portions alignable with said bores to supportsaid pinion gears.
 6. A differential assembly, comprising: a case havingfirst and second case apertures communicating with an internal chamber;a pair of output shafts having end segments disposed within saidchamber; a gearset disposed in said chamber for transmitting drive powerfrom said case to said output shafts while permitting speeddifferentiation therebetween and including a pair of laterally-spacedside gears coupled to said end segments of said output shafts; and aspacer pin assembly having a spacer ring, a cross pin and a fastener,said spacer ring is disposed in said chamber between said side gears andhas first and second spacer apertures alignable with said first andsecond case apertures, said cross pin is disposed within said alignedfirst and second case apertures and first and second spacer apertures,and wherein said fastener secures said cross pin to said spacer ring. 7.The differential assembly of claim 6 wherein said first case aperture insaid case defines a window opening sized to permit insertion of C-clipretainers into said internal chamber for securing said output shafts tosaid side gears.
 8. The differential assembly of claim 7 wherein saidspacer ring includes channels adapted to surround said C-clips.
 9. Thedifferential assembly of claim 6 wherein said case defines elongatedbores, and wherein said gearset further includes pinion gears eachmeshed with at least one of said side gears which are rotatablysupported in said bores so as to generally surround said spacer ring.10. The differential assembly of claim 9 wherein said spacer ring hasscalloped outer surface portions alignable with said bores to supportsaid pinion gears.